Upholstery installation and method of making same



May 12, 1936' 1.. H. DIEHL ET AL UPHOLSTERY INSTALLATION AND METHOD OF MAKING SAME Filed Dec. 23, 1932 2 Sheets-Sheet l SywGvvYQ'to/V Afqyazf [3501351 May 12, 1936 D|EHL ET A 2,040,365

UPHOLSTERY INSTALLATION AND METHOD OF MAKING SAME Filed Dec. 23, 1932 2 Sheets-Sheet 2 Patented May 12, 1936 urnons'rnnr msrmarroiz arm Mn'rnon or MAKING SAME I Lloyd H. Diehl and George T. Balfe, Detroit,

Mich., assignors to Detroit Gasket & Mfg. (30., Detroit, Mich., a corporation of Michigan Application December 23, 1932, Serial No. 648,692

14 Claims. (01.154 2) which it is the aim of this invention'to overcome. I v t For example, there are structure's wherein a suitable number of spaced slides or keyways are attachedto a base, and thereafter a spring clip is attached to the panelling by engagement in each ,slide or keyway. Another expedient with which 1 we are familiar, is the provision of anelongated slot in a foundation or body terminating in an opening through such base orbody, whereby a spring clip or fastener may be inserted after the trim cloth has been afflxed to the baseand before the completed panelling is attached to a body frame. In other constructions wherethefastener means is attached to the panel before applica-- tion of the trim cloth, lateral movement is allowed the studs or fasteners so that they are not held fixed and in the precise required locations.

Among the principal objections to conventional panelling are the relatively heavy, and hence undesirable, thick, board now required for strength and to afford a support for the clip fastening means. That is, such fastening means must be attached to the board by prongsor studs, which latter must not project through the board and therebymar the trim or other surface appearance,

Such board or base,moreover, has a tendency to warp due, we believe, to exposure to moisture and temperature conditions occasioned by seasonal changes. Another difficulty with the usual panelling is encountered in the assembling of the final article preparatory to its application to the body frame. For instance, w here the clips are inserted. as the final step in the production ofthe article,

this must be accomplished at theautomobile assembly plant and is objectionable for several reasons. First, the necessity of inserting the clips results in delay and holding up of the assembly line, as where the clips do not fit easily into the keyways.

ner that the hands of the workmen are frequently injured. Third, because of the need for haste at the assembly line, the clips may be only partially Second, in such cases it is necessary" that the clips be driven or forced in such a maninsertedor improperly placed in position so that they are not located in such manner as to properly register with the openings or sockets in the body frame. This latter is, of course, a very important objection in that where the clips are not uniformly located, the entire panelling must be discarded. A further objection to conventional constructions resides in the use of slidably or movably positioned fasteners or studs, since where such construction is employed, the fasteners work loose and move about to become unduly strained and distort the panel. Also, rattling and, squeaking frequently ensues, and, as we just pointed out above. the sliding or movable connection of the clips or fasteners also renders it extremely difficult to properly locate them for registration with the openings 'in the body frame. In other words, by such conin conventional structures, of applying the clips as the final step in the automobile plant before the panelling is attached to the body. This is necessary in order that the panels maybe stacked at the, factory and conveniently shippedto the automobile plant, and the final operation of inserting the clips is both expensive, tedious, and unreliablainsofar as it affects the positioning of the clips.

We. have found, furthermore, that conventional structures are subject to disastrous and expensive breakage when, for any'reason, the

.panelling must be removed and replaced, that is to say, the means for fastening, the clips to the board is often torn away or the clips or fasteners themselves are mutilated. Also, in con- PATIENT {Omar 7 struetions where the clips or studs project "through openings in a fibrousboard', there is and this condition is aggravated when any tearing or disruption of the openings takes place.

We have developed a coach work or upholstery studs are preferably fixed in position and the; shank andhead are freely movable in all direcpanel wherein (1) the bases, of the fasteners or A t1ons, and (2) a panel suitablyreinforoed to? assure both long life and maximum resistance to conditions normallypresent and surrounding the use of articles of this character.

With the panelling now to be described, we have taken into consideration the various, heretofore insuperable, difficulties and have obtained, by an efficient and economical method, a product having (1) increased wearing qualities, strength and resilience, i; e., resistance to shocks or blows;

signs; (4) substantially sound absorbent properties; (5) a minimum of adhesive, in fact, free as far as possible from any objectionable or unreliable gluing operations, the structure being positively united or secured together: (6) the fasteners precisely located and fixed, with no opportunity for moving or sliding and having such fasteners provided with shanks freely flexible in all directions; and (7) reinforcing means to prevent any possibility of warping] The product of thepresent invention, more over, is assembled at the factory as a unit having the body frame fastening'means fixed inposition and the complete panels are stacked and shipped to the automobileplant where they can be applied'from the assembly line without any fur- .fther operations. 35

smooth base for the fabric, or other trim as well as a coating, such as a suitable lacquer or finish.

The present panelling, moreoven provides a Referring to the drawings,

Figure 1 is a view showing a door panel in position;

Figure 2 is a view showing the various parts of the panel in position to be assembled and upon a suitable press;

Figure 3 is a sectional pa e m Figure 4 is a similar sectional view' showing the panel applied to a door frame;

view of our improved Figures 5"to 10, inclusive, illustrate various" types 'of' reinforcinglayers, in united'relation to 'theboard or base;

Figure 11 is a view representative of the various boards illustrated in Figures 5 to 10 having a coating oflacquer or other finishing material applied to the metallic surface;

Figure 12 isa. view of amodified type of pan elling wherein the board is attached'to opposite sides'of the reinforcement;

Figure 13 is a modification in which the reinforcement is applied in the form of strips to the marginal surfs/2e portions of the board;

v Figure 14 is a section on the line "-44 of Figure 13; and

' Figure 15 is a modified construction wherein the reinforcement is employed, as a marginal or edge binding, of substantiallyU-form.

Referring to the drawings, in Figure 1 we have illustrated a panel applied to the rear door of an automobile. This panel comprises a base Hi which in some cases is formed of sound absorbs ent material, and is usually constructed of a material having a-suitable body or rigidity such as cardboard, fiberboard, pressed board, a felted material, or paper-like material which is treated in such manner as to be rendered water and moisture resistant. Also, we use paper-like materials of fibers, cork and fibers, or laminated structures having bonded layers of fibers and cork andfibers including materials described in United StatesPatents Nos. 1,888,409 and 1,888,410.

We attach to this board a perforated sheet ll of thin metal, such as sheet steel, copper, or alloy metal and which sheet is provided with struck-up pr'oiectionsof various types and openings adjacent thereto; The'projections are embedded in the board by pressure, as shown in the drawings, and preferably terminate below the opposite surface of the board. In this manner, one surface of the panel comprises a perforated metal-sheet, while the opposite surface is smooth "and unobstructed, so as to 'nicely receive' and support a trim of fabric or a finish coating. p

The projections firmly'unite the metal sheet and board and obviate the use of adhesives and glues, which, inmany instances, prove unreliable when exposed. to weather, as in the case of the doors of motor vehicles, r

In Figure 5, we have shown projections struck up in the metal sheet in the form of protuberances i2 and tangs projecting from the apices thereof and forming openings It h s construction, is also shown in Figure 10, wherein the tan'gs. extend to the outer surfaceof the board and are bent over to lie within the plane. thereof and form a smooth unobstructed surface. A similar construction is also shown in Figure 12,

whereinthe metal reinforcing sheetconstitutes a core.

. In Figure 11, we have illustrated a board, as

shown in Figure 5, having protuberances and.

tangs wherein the tangs do not extend to the outer surface of the board, and wherein the metal surface is'provided with a coating of lacquer or other finish of suitable color. This construction,

shown in Figure 11,is highly suitable for. foot boards or cowl panels of automobiles, a relatively still or coarse paper or fiber web suitably waterproofed being preferably employed as the base,

and the material being useful in manyother 1 similar applications; It may betacked .or glued in position or suppliedwith studs or fasteners as'herein shown and described. It will be understood that the coating which we will designate by the numeral may be applied to any of the several constructions illustrated in Figures 5 to 12, and, in fact, is :also applied to the opposite surface of the board as well as to the perforated metal layer. 1 1 "j I r In Figure 6, the projections take the form of a relatively 1o ng ,tang at one side of the opening and a shorter tang at theopposite side, .while in Figure ,7 the tangs are of equallength. In Figure 8 single tanss or tongues are struck up from the 1 sheet and in Figure 9 such tangs extend through and have their ends bent over and clenched to hem the plane of the opposite surface of the board and form a smooth unobstructed surface. As stated, the various types of projections serve to bind the board toqthe reinforcement. The perforated sheet is stifle'ned'by reason of this construction, so that relatively thin gauge metal may be employed, and the projections ,impartfstrength to the board. By reason of this construction, a relatively thin board may be employed effecting a saving in this material and themetal reinforcement effectually prevents any possibility of warp- 8.

The tangs are arrangedin rowsand in some cases those of one row are in staggered relation to those of an adiacen't row.

portions l9.

' The projections are struck up in the metal, e resilient nd fl x e tuds havtheirbases sheet at a multiplicity of closely spaced points throughout the area of the sheet, thereby forming closely compacted or spaced perforations and projections, the metal sheet preferably, but not always, being coextensive with the base.

Further, the use of a metal reinforcing with these spring-like tongues or projections imparts a resiliency to the board and panel, whereby it will receive shocks and blows withoutbecoming permanently deformed.

, At the same time, however, since the board and the metal layer are relatively thin, I the panel may be bent or shaped to accommodate itself to various configurations or conditions encountered and when so deformed or shaped, will retain its new configuration. This is likewise true when designs or other figures are embossed in the panel material.

Since it is quite customary to form pockets on the panel, the metal sheet provides an effective anchor for the stitching of said pockets.

Referring to Figure 2, we have illustrated the board, the reinforcement and a layer of trim material i6 disposed in a suitable press, preparatory to forming the assembled panel. The press is formed with embossing dies for producing a suitable design or indentation ll. I

Referring to Figure 3, we have illustrated a panel after it has been formed by the compressing operation shown in Figure'2. It will be observed that we utilize fastening members in the form of studs having enlarged head portions I8,

reduced shanks, and wide, preferably flat base The base portions .are disposed in spaced recesses 20 formed in one surface of the board, such recesses being of a depth to allow the bases of the studs to lie flat andhave their upper surfaces preferably flush with the surface of the base to prevent formation of ridges in the reinby pressure, whereby the metal about. the base bf the stud will lie substantially flat and cooperate with the base to clamp the base of each stud firmly in position. The recesses are of a size to receive the base of each stud and substantially prevent any sliding movement thereof in any direction. The studs are inserted through openings 20' in the metal reinforcing layer, which openings are spaced in accordance with the openings or sockets 22 in the body frame 2| and the spacing of said recesses 20, the openings 20", 22 being of a size to pass the head and shank of the stud but prevent any shifting movement of the stud. In other words, when the stud or fastener is positioned as shown in Figure 3, with its foot or base clamped between the metal layer and the facing layer, the base of the stud or fastener is substantially fixed and is not capableof any substantial lateral or other sliding movement.

The studs or fasteners are preferably constructed of material which will permit them to flex or bend freely in all directions, such material being resilient, flexible, or compressible and of sufiicient strength to properly and firmly support the panel without sagging. We use studs or fastenersmade of such materials as molded rubber, molded cork, molded cork and rubber mixtures, as well as flexible metal fasteners or studs having compressible heads, and flexible and resilient types of fasteners, there being many commercial varieties of so-called snap fasteners available. We prefer a stud or fastenerwhich is bendable in all directions but which will not permanently deform. I

fixed in position, such bases being, for all practical purposes, immovable. The studs'or'fasteners are bendable about their substantially fixed bases in all directions to take care of any irregularities in registration of the studs with the sockets or openings in the frame. This condition often exists initially, and frequently results from use of the vehicle, due to loosening up or shifting of the body frame,.and we find that a stud havinga resilient and flexible shank is highly efllcle'nt. Again, such studs provide a cushion suillcient to insert them. Since the bases or feet of the stud are firmly and permanently held, the panel is easily removable in thatxth'e heads of the studs will spring out of the sockets upon ap plication of a light pressure or'leverage. Equally important in this connection is the practical elimination of the possibility of tearing the stud from the panel and thereby ruining the installation.

The head of the stud or fastener may be of any suitable configuration, determined by the opening or socket in the body frame in which it is adapted to be inserted. In Figure 4, I have illustrated the panel applied to the body frame 2| with the stud extending through an opening 22 therein and having its enlarged head engaging the opposite wall of the frame.

By the construction described, when the partsare compressed together, the reinforcing layer is firmly affixed to the board clamping thestud in position and since the opening in the reinforcement is just large enough to receive the stem of the fastener, the fastener is firmly fixed and located. Moreover, since a flexible stud of rubber or other penetrable material is employed, the projections will extend into the base of the fastene'r to additionally anchor it in position.

Where a resilient stud of metal is emplo ed, it will understood that the opening, likewise will be of a size to pass the head and shank, and the foot will aot'as a stop for the projections, bending'them over and providing in effect a cushion for the base of the fastener when the parts are compressed together as shownin, Figure 3.

In producing the recesses 2|! and openin s 2!! respectively, in the board and reinforcement. we

use similar dies whereb when the two layers are assembled. the op nings exactly and precise- 1y re ister with the recesses or vice versa.

With the several parts in position as shown in Fi ure2. the operation of the press will serve to unite the board Hi and reinforcement I! and e a ply a water. moisture and t mperature. res stant glue r a esive coatin to either of the adjacent o posed SuTFa s of th board nr trim; or to both of such surfaces. so that theirim is like-' wise united to the smooth, unobstructed surface of the board. In this connection, the press will carry suitable embossing dies 23 to produce the desired configuration l1, and the d es will also be formed to receive the studs I8, which, as will be understood, are inserted in the openings in the metal layer preliminary to the uniting operation.

In Figures 13 and 14, we have shown a construction wherein strips 25 of the metal reinforcement are applied at the marginal edges'of' the board and wherein the studs or fasteners are with the coextensive metallic pomtioned in the manner herein described. This expedient is used where it is not desired to have a metal layer'coextensive with the board but the closely compacted projections are employed'as layer shown in the other figures-of the drawings.

'In Figure 15,-we have illustrated a modification wherein the reinforcing takes the fonnof a binding of substantially U-shape I. about the exposed edge of-the'board with the projections embedded in the board, as heretofore described, and the stud or fastener similarly clamped in accordance with the other structures.

' In employing a flexible or resilient stud such as one of rubber, we are enabled to'zapply the thereafter stack the complete panels for shipment to the automobile plant and assemblylina: The studs will readily flex for this purpose'and assume their normal position. when the pressure is removed in a stack 7 7 j By providing a perforated metal reinforcement and particularly one having a multiplicity of per-' forations and projections closely spaced over its entire area, the panel is strengthened and render'ed sound absorbent.

It will be observed that the studs or fasteners are fixed in proper spaced relation and for all material-purposes theirbases are immovable, as distinguished from prior structures wherein the studs are-bodily movable as a whole. r

'As heretofore stated, instead of using a fabric trim l6, we coat the smooth surface of the board, as well as the metal surface, with any suitable finish or lacquer. In Figure 3,'-'we have illustrated the free marginal edges of the trim or fabric "turned over and united to the metal sheet. This union is accomplished through the medium of a suitable water-proof adhesive or glue similar to that which will be applied for uniting the trim to the face of the base of theboard. Such overlapping portion provides a cushion or-layer 28 between the panel and the base of the frame 2| asin'FlgureL It isto be observed that'the fastener is positioned without the-necessity of piercing the board and also that the tongues or projectionspreferably do not extend to the opposite opposed surface of the board. Where the projections extend through,'they are bent over to be flush withor lie within the plane of-the exposed surface' of the board, their free endsbeing preferably clenched nto'the base with the end edges not exposed and the. surface is free of projecting portions. 'I'herefore, the board has a smooth unobstructed surface. and the trim is very nicely applied and fits the board to obtain a verydesirable panel.

The studs or fasteners will be applied usually along three sides of the panel. but'may be applied to'one, two, or' all four sides, andin such number as required.

In Figure'ywhere we have shown the panel in section'applied to the body frame, it will be understood that while the frame'is illustrated as having an opening 22 receiving the fastener i8, this may take the form ofa rigid or resilient socket as desired. In fact, various types of separable fastener constructions may be used as found most convenient, preferably, however, of a'ilexible type, that is, a fastener which may be flexed or bent without permanently or objectionably distorting.

75 It is to be noted that in any of the embodiaccuses stud at the time of manufacture of the panel, and

movementof the studs. Alsothe stud may pro-- mentsof fthe inventiomthe metal or reinforcing constitutes a -continuous for ing' thespaoed relation offthe studsor fasteners.

That is; the openings in the continuous sheet or strip of'reinforceme'nt as'surethe proper align-V inent' and registered location of the fasteners. The reinforcing and thewallsol the openings cooperate with the board to prevent any'substanus; movement of the bases of the studs or the stud as a whole-where a'rigid stud is used, but 1 donot interfere 'withfthe'flexing of the shanks of theresilient or bendable'studs.

Whilewe havefindicated that the bases 0 the studs we may, insome cases, enlarge theopenings in" the metal and the recesses in u the board or base to allow m a limited shifting ject through openings inithe' baseformed centrally ofthe recesses!!! andithe reinforcing layer of metal receive the tumor-coating. We prefer, however, that the studs project through the reinforcing layer as, shownleaving the basewith a smooth unobstructed surface.

' In assembling the panel, as in Figure 2, it will be noted'that the layers are superposed so that 26 the tangs extend in'on'e direction and the studs in the opposite direction. Where the; studs pro ject through the ibasefboth extend in the same direction, and the. trim-"i is j superposed on the metal layer. As stated, astratum of suitable 30 adhesiveis disposed betwee" the trim :and the 1 layer to which it is applied? We will, in some cases,ralso unite a metal layer, as shown herein, to each side of the base, one such layer receiving the trim ofifioating and the 6 studs extending out from the opposite layer as shown and described.

Thetangs orprojections I! may be of any suitable length and the board likewise of varying thickness, but we prefer a thin board and hence 49 the tang'or mugs and protuberances are of minimum length to obtainthe desired result.

. 'I'he metalis heat resistant and heat conductive .and thetangs tend to transfer heat away from the interior'of'the car."

In some 1cases,m'eansare provided operating with the press, to fold over the marginal portions 2 B of the trim'andunitethe sameto the adjacent layerof' the panel simultaneous with the pressingoperation. I

Various modifications of theinvention may be the appended claims. j I

1. A panel compiisingya base layer and are- 5 inforcing layer, and fastening, means freely flexible in all directions, said fastening means comprising studs, one end of each stud ilxedto the" panel and extending through openings in the reinforcing layer. .I I

'2. A panel comprising a .base having one surface substantially smooth and unobstructed and ameta layer having a multiplicity of struckup projections embedded in 'said :base and uniting resorted to.all of which are comprehended within,

said'layer thereto, forming a perforated metal surfaceon the opposite Side of. said base, and studs or fasteners extending from said panel and clamped in fixed spaced relation between said metal layer and said base. f I I 3. A panel comprising a base having one surface substantially smooth and unobstructed, and I a metal layerjsubstantially coextensive therewith having a multiplicity of. struck up projections extending throughout the area of the metal layer, and embedded in said base and uniting. said,

layer thereto, forming a perforated metal surface on the opposite side of said base, and spaced studs or fasteners of rubber extending from the marginal area of the panel on one side thereof.

5. A panel comprising a base having one surface substantially smooth and unobstructed, and a metal layer having a multiplicity of struck up projections embedded in said base and uniting said layer thereto, forming a perforated metal surface on the opposite side of said base, and spaced studs or fasteners extending through openings in the marginal area of the metal layer --and confined thereby."

6. A panel comprising a base having one surface substantially smooth and unobstructed, and a metal layer substantially coextensive therewith having a multiplicity of struck up projections extending throughout the area of the metal layer, and embedded in said base and uniting said layer thereto, forming a perforated metal surface on the opposite side oi. said base, and spaced studs or fasteners extending from the marginal area of the panel, said studs or fasteners having enlarged bases, the bases of said studs or fasteners being clamped in position between said metal layer and said base.

'7. A panel comprising a base having one surface substantially smooth and unobstructed, and a metal layer substantially coextensive therewith having a multiplicity of struck up projections extending throughout the area of the metal layer,

and embedded in said base and uniting said layer thereto, forming a perforated metal surface on the opposite side of said base, and spaced studs or fasteners extending from the marginal area of the panel, said studs or fasteners having enlarged bases, the bases of said studs or fasteners being engaged on opposite sides by said metal layer and said base to clamp the studs in fixed position, and said studs extending through openings in'said metal layer.

8. A panel comprising a relatively thin fibrous base having one surface substantially smooth and unobstructed, and a relatively thin metal layer substantially coextensive therewith and having a multiplicity of struck up projections extending throughout its area, the projections embedded in said base and uniting said layer thereto, forming a perforated metal surface on the opposite side of the base, and flexible fasteners or studs having enlarged bases interposed between said base and said metal layer and held clamped in fixed position thereby, said studs or fasteners extendingthrough openings in the metal layer, and a layer of trim material ad--v hesively united to the smooth and unobstructed surface of said base and having its marginal edges united to said metal layer.

9. The method of making a panel which comprises superposing a layer of perforated metal having projections and confining studs or fasteners upon a layer of base material superposed on a layer of trim and between which latter layers is 'a stratum of adhesive, with the projections extending toward the base and the studs or fasteners extending in the opposite direction, uniting the respective layers by pressure and embedding the projections in said base and clamping the studs or fasteners in position.

l0..A panel comprising a layer of base material having a substantially smoothv continuous surface on one side, a multiplicity of recesses on the other side of said layer, a metal layer having openings therein and united to the base layer on said last mentioned side, and studs having their bases in said recesses and their stems extending through said openings.

11. A panel comprising a layer of base material having a smooth continuous surface on one side, a multiplicity of recesses on the other side, a metal layer having openings therein and provided with'proiections embedded in said base layer for uniting the layersyand studs having their bases in said recesses and their stems extending through said openings.

12. A panel comprising a layer of base material having a substantially smooth continuous surface on one side, a multiplicity of recesses on the other side of said layer, a metal layer having openings therein and united to the base layer on said last mentioned side, and studs flexible in -all directions having their bases in said recesses and their stems extending through said. openings.

13. A panel comprising a layer of base material having a substantially smooth continuous surface on one side, a multiplicity of recesses on the other side of said layer, a metal layer having openings therein and united to the base layer on said last mentioned side, and rubber studs having their bases in said recesses and their stems extending through said openings.

14. A panel comprising a layer of base Hi8. terial having a smooth continuous surface on one side, a layer of trim cloth covering said side, a multiplicity of recesses on the other side of said layer, a metal layer having openings therein and united to the base layer on said last mentionedsida'and studs having their bases in said recesses and their stems extendingthrough said openings.

LLOYD E. DIEHL. GEORGE T. BALFE. 

